Overhaul
DISASSEMBLY
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Check that SST is securely fitted onto the generator rotor shaft.
b. Mount SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2.
d. To loosen the generator pulley nut, turn SST 1-A in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the generator pulley nut by more than one-half turn.
e. Remove the generator from SST 2.
f. Turn SST 1-B, and remove SST 1-A and B.
g. Remove the generator pulley nut and generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the nut and terminal insulator.
b. Remove the nut, screw and rectifier plate.
c. Remove the 2 nuts and the rear end cover.
d. Remove the brush cover from the generator brush holder assembly.
e. Remove the 3 screws and the generator brush holder assembly.
f. Remove the plate seal.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
a. Remove the 2 screws and the generator regulator assembly.
4. REMOVE GENERATOR HOLDER WITH RECTIFIER
a. Remove the 3 screws and the generator holder with rectifier.
5. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the 3 terminal insulators from the generator rectifier end frame.
b. Remove the 4 nuts and the cord clip.
c. Using SST, remove the generator rectifier end frame.
SST 09286-46011
d. Remove the plate retainer.
e. Remove the generator rotor assembly from the generator drive end frame.
NOTE: Do not drop the generator rotor assembly.
HINT: If the generator rotor is engaged too firmly, gently tap the generator rotor shaft to remove it using a plastic hammer.
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator rotor assembly.
NOTE: Do not drop the generator rotor assembly.
b. Install the generator rotor assembly and the plate retainer.
c. Using a 30 mm socket wrench and press, slowly press in the generator rectifier end frame.
d. Install the 4 nuts and the cord clip.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
e. Install the 3 terminal insulators onto the generator rectifier end frame.
2. INSTALL GENERATOR HOLDER WITH RECTIFIER
a. Install the generator holder with rectifier with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
3. INSTALL GENERATOR REGULATOR ASSEMBLY
a. Install the generator regulator assembly with the 2 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Install the plate seal.
b. Install the generator brush holder assembly with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
c. Install the brush cover onto the generator brush holder assembly.
d. Install the rear end cover with the 2 nuts.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)
e. Install the rectifier plate with the nut and screw.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf) for bolt
f. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
5. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install the generator pulley onto the generator rotor shaft by tightening the generator pulley nut by hand.
b. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.
Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
NOTE: Check that SST is securely fitted onto the generator rotor shaft.
c. Mount SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2.
e. Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 133 N.m (1,356 kgf.cm, 98 ft.lbf)
f. Remove the generator from SST 2.
g. Turn SST 1-B, and remove SST 1-A and B.
h. Turn the generator pulley, and check that the generator pulley moves smoothly.